Kawasaki Ninja 300 Assembly & Preparation Manual

Brand: Kawasaki

Model: Ninja 300

Category: Motorcycles

Type: Assembly & Preparation Manual

This manual is also suitable for

Ninja 300 ABS

Kawasaki Ninja 300 ABS is a motorcycle that has been partially disassembled for shipping purposes. Once assembled, it offers a range of capabilities:

Battery: The sealed battery never needs refilling and has been activated for optimal performance.
Brakes: The front and rear brake discs have been cleaned using oilless solvent to ensure effective braking.
Cables and Hoses: All cables, wiring leads and hoses have been correctly routed for smooth operation.
Clutch: The clutch cable has been greased and correctly fitted for efficient gear shifting.

Kawasaki Ninja 300 ABS is a motorcycle that has been partially disassembled for shipping purposes. Once assembled, it offers a range of capabilities:

Battery: The sealed battery never needs refilling and has been activated for optimal performance.
Brakes: The front and rear brake discs have been cleaned using oilless solvent to ensure effective braking.
Cables and Hoses: All cables, wiring leads and hoses have been correctly routed for smooth operation.
Clutch: The clutch cable has been greased and correctly fitted for efficient gear shifting.

Ninja 300

Ninja 300 ABS

Motorcycle

Assembly & Preparation

Manual

Foreword

In order to ship Kawasaki vehicles as effi-

ciently as possible, they are partially disassem-

bled before crating. Since some of the most

commonly removed parts have a direct bear-

ing on a vehicle’s reliability and safety, consci-

entious pre-sale assembly and preparation be-

comes extremely important. Good setup pro-

cedures can prevent needless warranty claims

and give customers a greater sense of c onfi-

dence in Kawasaki and their Kawasaki Dealers.

This Assembly and Preparation Manual ex-

plains step by step procedures of the follow-

ing items for the Kawasaki Ninja 300, Ninja 300

ABS.

1. Uncrating

2. Assembly

3. Preparation

The selling dealer assumes sole responsibil-

ity for any unauthorized modifications prior to

sale. Refer to your Service Binder for any Ser-

vice Bulletins specifying Factory Directed Mod-

ifications (Special Claims) which must be per-

formed before the vehicle is ready for sale.

Whenever you see the following symbols

heed their instructions! Always follow safe

operating and maintenance practices.

DANGER

DANGER indicates a hazardous situa-

tion which, if not avoided, will result in

death or serious injury.

WARNING

WARNING indicates a hazardous situa-

tion which, if not avoided, could result

in death or serious injury.

NOTICE

NOTICE is used to address practices not

related to personal injury.

NOTE

○This note symbol indicates points of particular

interest for m ore efficient and convenient op-

eration.

Kawasaki Heavy Industries, Ltd. accepts no

liability for any inaccuracies or omissions in this

publication, although every possible m easure

has been taken to make it as complete and ac-

curate as possible. All procedures and specifi-

cations subject to change without notice.

Table of Contents

crating ......................................................................................

Opening Crate ............................................................................. 3

Parts C heck ................................................................................. 4

sembly ......................................................................................

Handlebar.................................................................................... 5

Cables, Harness and Hoses Routing .......................................... 6

lutch Cable................................................................................

Windshield and Rear View Mirrors (Left and Right) .................... 7

Brake Disc Cleaning.................................................................... 7

reparation ...................................................................................

Battery Service ............................................................................ 7

Front Brake.................................................................................. 12

Rear Brake .................................................................................. 13

Clutch Lever and Cable............................................................... 14

Drive Chain.................................................................................. 15

Rear Shock Absorber .................................................................. 17

Tire Air Pressures........................................................................ 17

Fuel ............................................................................................. 17

Coolant ........................................................................................ 17

Engine Oil (4-stroke) ................................................................... 18

Idle Speed Adjustment ................................................................ 19

Throttle Grip and Cable ............................................................... 20

Rear Brake Light Switch.............................................................. 20

Headlight Aim .............................................................................. 20

Digital Meter ................................................................................ 21

License Plate Mounting Holes..................................................... 22

Fastener Check ........................................................................... 24

Standard Torque Table ................................................................ 26

Test Ride the Motorcycle ............................................................. 26

A & P Check List ......................................................................... 26

UNCRATI

NG 3

Uncrating

Opening Crate

WARNING

Crates

have sharp edges and may have

nails or screws that can cause cuts and

injury. Always wear protective gloves,

boots

and eye protection when uncrat-

ing to prevent injury.

WARNING

The

steel crate panel plates and fasten-

ers have sharp edges. Always wear pro-

tective gloves, boo ts and eye protection

en uncrating to prevent injury.

•

Clear a space about 6 m (20 ft) square to give

yourself plenty of space to work.

•

Place the crate upright on its base.

•

Remove the cardboard cover.

•

Remove the parts box.

NOTICE

When removing the crate bracket from

the motorcycle, be careful not to drop

any parts or the bracket onto the fuel

tank and other components, and not to

scratch the fuel tank or other compo-

nents with the crate bracket.

•

Remove the four bolts (D = 8, L = 20) to re-

move the left and right handlebars and dis-

card bolts.

•

And then remove the lower bolts (D = 8, L =

18) on the bracket and discard them.

•

Remove the upper bolts (D = 8, L = 16) to

take off the crate bracket and foam pad and

discard them.

A. Bolts (D = 8, L = 20)

B. Lower Bolts (D = 8, L = 18)

C. Upper Bolts (D = 8, L = 16)

Crate Bracket

E. Foam Pad

•

Take out all the bolts and screws and remove

the top and sides of the crate.

•

Lift the vehicle upward to remove the under

support. Lower the vehicle and roll the vehicle

off the crate.

4 UNCRAT

ING

Parts Check

•

Open the parts box, and check the parts against the illustrations. There may be minor differences

between these illustrations and the actual vehicle parts. In the following charts under Remarks, D

= diameter in millimeters, and L = length in millimeters.

No. Part Name Qty Remarks

1 Plug, Socket Bolt, Handlebar 4 D = 14.5

2 Socket Bolt, Handlebar 4 D = 8, L = 22

ocket Bolt, Rear View Mirror and Windshield

4 D = 6, L = 25

Left Rear View Mirror

5 Right Rear View Mirror 1

6 Windshield 1

7 Battery Electrolyte, FTX9-BS 1

8 Owner’s Manual 1

ASSEMBL

Assembly

Handlebar

•

Install the right handlebar with the mounting

bolts (

D = 8, L = 22) in place.

•

Install the left handlebar in the same manner

as the right handlebar.

•

Tight

en the right and left handlebar mounting

bolts to the specified torque.

Torque: 25 N·m (2.5 kgf·m, 18 ft·lb)

A. Right Handlebar

B. Mounting Bolts (D = 8, L = 22)

•

Install the plugs (D = 14.5) on each mounting

bolt top securely.

A. Plugs (D = 14.5)

6 ASSEMB

Cables, Harness and Hoses Routing

•

Check that the cables, wiring leads and hoses are routed correctly.

A. Front Brake Hose

B. Right Switch Housing Harness

C. Clutch Cable

D. Left S witch Housing Harness

E. Throttle Cables

F.Viewed Front

G. Viewed Left Side

PREPARA

TION 7

Clutch Cable

•

Apply a light coat of grease on the clutch inner

cable.

•

Line up the slots on the clutch lever, locknut,

and adjuster.

•

Fit the tip of the clutch inner cable into the

lever socket, slide the inner cable through the

slots, and release the outer cable into the ad-

juster.

A. Clutch Cable

B. Adjuster

C. Locknut

D. Cable Tip

Clutch Lever

Windshield and Rear View Mirrors

(Left and Right)

•

Fit the windshield onto the upper fairing, and

install each rear view mirror with the two

socket bolts (D = 6, L = 25).

•

Install other mirror with the two socket bolts

(D = 6, L = 25).

•

Tighten all socket bolts (D = 6, L = 25) se-

curely. Be careful not to overtighten them.

A. Windshield

B. Upper Fairing

C. Left and Right Rear View Mirrors

D. Socket Bolts (D = 6, L = 25)

Brake Disc Cleaning

•

Clean the front and rear brake discs using

oilless solvent.

WARNING

An anticorrosive treatment applied to

the brake discs will increase braking

distance and can cause an accident

resulting in serious injury or death. Re-

move the anticorrosive treatment using

an oilless solvent.

Preparation

Battery Service

Battery Removal

The battery used in this motorcycle is a sealed

type and never needs to be refilled. Follow the

procedure for activating a new battery to ensure

the best possible battery performance.

8PREPAR

ATION

•

Remove the bolt (D = 5, L = 16) and collar (D

= 5.8) on the left and right side covers.

•

Pull the left and right side covers to the out-

side for detaching the projections.

A. Side Cover

B. Bolt (D = 5, L = 16) and Collar (D = 5.8)

C. Projections

•

Remove the bolts (D = 6, L = 18) and collars

(D = 6.8) on the front seat, and pull off the

front seat to the up and rear.

A. Bolt (D = 6, L = 18) and Collar (D = 6.8)

B. Front Seat

C. Pull Up and Rear

•

Remove the battery cover screw (D = 5, L =

16) and pull up the battery cover with the relay

box.

A. Relay Box

B. Battery Cover

C. Battery Cover Screw (D = 5, L = 16)

•

Take the battery out of the rear fender.

A. Battery

•

Clean the terminals.

Battery Activation

Electrolyte Filling

•

Make sure that the model name of the elec-

trolyte container matches the model name of

the battery. These names must be the same.

Battery Model Name

EX300A/B: FTX9-BS

A. Model Name of the Electrolyte

B. Model Name of the Battery

PREPARA

TION 9

NOTICE

Each battery comes with its own specific

electrolyte container; using the wrong

container may overfill the battery with

incorrect electrolyte, w hich can shorten

battery life and deteriorate battery per-

formance. Be sure to use the electrolyte

container with the same model name as

the battery since the electrolyte volume

and specific gravity vary with the battery

type.

NOTICE

Do not remove the aluminum sealing

sheet from the filler ports until just prior

to use. Be sure to use the dedicated

electrolyte container for correct elec-

trolyte volume.

DANGER

Sulfuric acid in battery electrolyte can

cause severe burns. To prevent burns,

wear protective clothing and safety

glasses when handling electrolyte. If

the electrolyte comes in contact with

your skin or eyes, wash the area with

liberal amounts of water and seek medi-

cal attention for more severe burns.

•

Place the battery on a level surface.

•

Check to see that the sealing sheet has no

eeling, tears, or holes in it.

•

Remove the sealing sheet.

NOTE

○The battery is vacuum sealed. If the sealing

sheet has leaked air into the battery, it may

require a longer initial charge.

A. Sealing Sheet

B. Filler Ports

•

Remove the electrolyte container from the

vinyl bag.

•

Detach the strip of caps from the container

and set aside, these will be used later to seal

the battery.

NOTE

○Do not

pierce or otherwise open the sealed

cells of the electrolyte container. Do not at-

tempt to separate individual cells.

A. Strip of Caps

Sealed Cells

•

Place the electrolyte container upside down

with the six sealed cells into the filler ports

of the battery. Hold the container level, push

down to break the seals of all six cells. You

will see air bubbles rising into each c ell as the

ports fill.

NOTE

○Do not tilt the electrolyte container.

•

Check the electrolyte flow.

•

If no air bubbles are c oming up from the filler

ports, or if the container cells have not emp-

tied completely, tap the container a few times.

NOTE

○Be careful not to have the battery fall down.

10 PREPA

RATION

A. Air Bubbles

B. Ta

p the Container

•

Keep the container in place. Don’t remove

the container from the battery, the battery re-

quires all the electrolyte from the container for

proper operation.

NOTICE

Removal of the container before it is

completely empty can shorten the ser-

vice life of the battery. Do not remove the

container until it is completely empty.

•

After filling, let the battery sit for 20 ∼ 60

minutes with the electrolyte container kept in

place, which is required for the electrolyte to

fully permeate into the plates.

•

Make sure that the container cells have emp-

tied completely, and remove the c ontainer

from the battery.

•

Place the strip of caps loosely over the filler

ports, press down firmly with both hands to

seat the strip of caps into the battery (don’t

pound or hammer). When properly installed,

the strip of caps will be level with the top of

the battery.

A. Strip of Caps

NOTICE

Once the strip of caps is installed onto

the battery, never remove the caps, nor

add water or electrolyte to the battery.

NOTE

○Cha

rging the battery immediately after filling

can shorten service life.

Initial Charge

•

New

ly activated sealed batteries require an

initial charge.

Standard Charge: 0.9 A × 5 ∼ 10 hours

•

If using a recommended battery charger, fol-

low the charger’s instructions for newly acti-

vatedsealedbattery.

Kawasaki-recommended chargers:

Battery Mate 150-9

OptiMate PRO 4-S/PRO S/PRO 2

Yuasa MB-2040/2060

Christie C10122S

•

If the above chargers are not available, use

equivalent one.

•

Let battery sit 30 minutes after initial charge,

then check v oltage using a voltmeter. (Volt-

age immediately after charging becomes tem-

porarily high. For accurate measuring, let the

battery sit for given time.)

PREPARA

TION 11

NOTE

○Charging rates will vary depending on how

long th

e battery has been stored, tempera-

ture, and the type of charger used. If voltage

is not at least 12.6 volts, repeat charging cy-

cle.

○To ensure maximum battery life and customer

satisfaction, it is recommended the battery be

load t

ested at three times its amp-hour rating

for 15 seconds.

Re-check voltage and if less than 12.6 volts

repe

at the charging cycle and load test. If still

below 12.6 volts the battery is defective.

Battery Installation

•

Turn

the ignition switch off.

•

Run the red capped (positive) cable (+) cor-

rectly.

A. Red Capped (Positive) Cable (+)

B. Main Harness

C. Ma

in Fuse

D. Run the red capped (positive) cable (+)

above the main harness at the main

use side.

Run the red capped (positive) cable (+)

under the main harness at the terminal

side.

•

Place the battery into the rear fender.

•

Connect the red capped cable to the (+) ter-

minal, and then connect the black cable to the

(–) terminal.

•

Put a light coat of grease on the terminals to

prevent corrosion.

•

Cover the (+) terminal with its protective cap.

•

Insert the tab of the battery cover into the hole

of the frame.

A. Hole

B. Tab

C. Battery Cover

•

Install the battery cover screw (D = 5, L = 16)

and tighten it securely.

•

Insert the tabs on the rear of the front seat into

the slots on the frame.

A. Front Seat

B. Tabs

C. Slots

D. Insert

•

Install the collars (D = 6.8) and front seat bolts

(D=6,L=18).

•

Tighten the front seat bolts securely.

•

Insert the projections of the left side cover into

the grommets.

12 PREPA

RATION

A. Projections

B. Left Side Cover

C. Gr

ommets

•

Install the collar (D = 5.8) and side cover bolt

(D=5,L=16).

•

Tighten the side cover bolt s ecurely.

•

Install the right side cover in the same manner

as the left side cover.

Front Brake

Front Brake Fluid Level Inspection

•

With the front brake fluid reservoir held hori-

zontal, check that the fluid level is above the

lower level line.

A. Front Brake Fluid Reservoir

B. Lower Level Line

•

If the fluid level in the reservoir is lower than

the lower level line, check for fluid leaks in the

front brake lines and fill the reservoir.

•

Loosen the screws to remove the front brake

fluid reservoir cap and diaphragm.

•

Fill the reservoir to the upper level line with

DOT3 or DOT4 brake fluid. Inside the front

brake reservoir is a stepped line showing the

upper level line.

A. Front Brake Fluid Reservoir

B. Upper Level Line

WARNING

When working with the disc brake, ob-

serve the precautions listed below.

•

Never reuse old brake fluid.

•

Do not use fluid from a container that

has been left unsealed or that has been

open for a long time.

•

Do not mix two types and brands of

fluid for use in the brake. This lowers

the brake fluid boiling point and could

cause the brake to be ineffective. It

may also cause the rubber brake parts

to deteriorate.

•

Don’t leave the reservoir cap off for

any length of time to avoid moisture

contamination of the fluid.

•

Don’t change the fluid in the rain or

when a strong wind is blowing.

•

Brake fluid quickly ruins painted sur-

faces; any spilled fluid should be com-

pletely wiped up immediately.

•

If any of the brake line fittings or the

bleed valve is opened at any time,

the AIR MUST BE BLED FROM THE

BRAKE LINE.

•

Operate the brake lever several times.

•

If it feels spongy, there might be air in the

brake line.

•

If necessary, bleed the air in the front brake

lines.

•

Also check for fluid leakage around the fit-

tings.

BrakeLineAirBleeding

•

Loosen the screws to remove the reservoir

cap and diaphragm, and check that there is

plenty of fluid in the reservoir.

PREPARA

TION 13

NOTE

○The fluid level must be checked several times,

during

the bleeding operation and replenished

as necessary. If the fluid in the reservoir runs

completely out any time during bleeding, the

bleed

ing operation must be repeated from the

beginning since air will have entered the line.

•

Attach a clear plastic hose to the bleed valve

on the front brake caliper and run the other

end of the hose into a container.

•

With the reservoir cap off, slowly pump the

brake lever several times until no air bubbles

can be seen rising up through the fluid from

the holes at the bottom of the reservoir. This

bleeds the air from the brake master cylinder

end of the line.

•

Pump the brake lever a few times until it

becomes hard and then, holding the lever

squeezed, quickly open (turn counterclock-

wise) and close the bleed valve. Then release

the lever. Repeat this operation until no more

air can be seen coming out into the plastic

hose.

A. Hold the brake lever applied.

Quickly open and close the bleed valve.

C. Release the brake lever.

•

When air bleeding is finished, check that the

fluid level is between the upper and lower

level lines.

•

Install the diaphragm and reservoir cap.

•

Tighten the bleed valve to the specified

torque.

Torque:

5.5 N·m (0.56 kgf·m, 49 in·lb)

•

Apply the brake forcefully for a few seconds,

and check for fluid leakage around the fittings.

Rear Brake

Rear Br

ake Fluid Level Inspection

•

With the rear brake fluid reservoir held hor-

izontal, check that the fluid level is between

the upp

er and lower level lines.

A. Rear Brake Fluid Reservoir

B. Upper Level Line

C. Lower Level Line

•

If the fluid level in the reservoir is lower than

the lower level line, check for fluid leaks in the

brake line, and fill the reservoir.

•

Loosen the reservoir cap stopper screw to re-

move the reservoir cap and diaphragm, and

fill the reservoir to the upper level line with

DOT4 brake fluid, and reinstall diaphragm

and reservoir cap.

NOTE

○First, tighten the rear brake fluid reservoir cap

clockwise by hand until slight resistance is felt

indicating that the cap is seated on the reser-

voir body, then tighten the cap an additional

1/6 turn while holding the brake fluid reservoir

body.

14 PREPA

RATION

A. Reservoir

B. Reservoir Cap

C. Clockwise

D. 1/6 turn

•

Operate the brake pedal several times.

•

If it feels spongy, there might be air in the

brake line.

•

If necessary, bleed the air in the rear brake

line.

•

Also check for fluid leakage around the fit-

tings.

Brake Line Air Bleeding

•

Loosen the reservoir cap stopper screw to re-

move the reservoir cap and diaphragm, and

check that there is plenty of fluid in the reser-

voir.

NOTE

○The fluid level must be checked several times,

during the bleeding operation and replenished

as necessary. If the fluid in the reservoir runs

completely out any time during bleeding, the

bleeding operation must be repeated from the

beginning since air will have entered the line.

•

Attach a c lear plastic hose to the bleed valve

on the rear brake caliper and run the other

end of the hose into a container.

•

With the reservoir cap off, slowly pump the

brake pedal several times until no air bub-

bles can be seen rising up through the fluid

from the holes at the bottom of the reservoir.

This bleeds the a ir from the rear brake master

cylinder end of the line.

•

Pump the brake pedal a few times until it

becomes hard and then, holding the pedal

pushed down, quickly open (turn counter-

clockwise) and close the bleed valve. Then

release the pedal. Repeat this operation until

no more air can be seen coming up into the

plastic hose.

A. Hold the brake pedal applied.

B. Quickly open and close the bleed valve.

Release the brake pedal.

•

When air bleeding is finished, check that the

fluid level is between the upper and lower

level lines.

•

Tighten the bleed valve to the specified

torque.

Torque: 5.5 N·m (0.56 kgf·m, 49 in·lb)

•

Install the diaphragm and reservoir cap.

NOTE

○First, tighten the rear brake fluid reservoir cap

clockwise by hand until slight resistance is felt

indicating that the cap is seated on the reser-

voir body, then tighten the cap an additional

1/6 turn while holding the brake fluid reservoir

body.

•

Tighten the reservoir cap stopper screw.

•

Apply the brake forcefully for a few seconds,

and check for fluid leakage around the fittings.

Clutch Lever and Cable

Clutch Lever Free Play Inspection

•

Check that the clutch lever has the specified

amount of free play.

Clutch Lever Free Play:

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

PREPARA

TION 15

A. Adjuster

B. Locknut

C. 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

•

If the free play is incorrect, adjust the free

play.

Clutch Lever Free Play Adjustment

•

Turn the adjuster so that the clutch lever will

have 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of free play.

•

If it cannot be done, use the adjusting nuts on

the lower end of the clutch cable.

•

Slide the dust cover, and loosen the adjusting

nuts on the lower end of the clutch cable.

•

Adjust the free play.

WARNING

Operation with incorrectly routed or im-

properly adjusted cable could result in

an unsafe riding condition. Be sure the

cable is routed correctly and properly

adjusted.

A. Dust Cover

B. Adjusting Nuts

C. Clutch Cable

•

Tighten the adjusting nuts, and slide the dust

cover back into place.

NOTE

○After the adjustment is made, start the engine

and che

ck that the clutch does not slip and

that it releases properly.

○For minor corrections, use the adjuster at t he

clutc

h lever.

Drive Chain

Drive Chain Slack and Wheel Alignment

Inspection

•

Set the motorcycle up on its side stand.

•

Make sure that the drive chain has the speci-

fied amount of play, and that the left and right

notches are on the same marks or points on

the left and right of the swingarm.

WARNING

Misalignment of the wheel will result in

abnormal tire wear and can cause an un-

safe riding condition. Be sure the wheel

is properly aligned.

•

Rotate the rear wheel to find the position

where the chain is tightest, and measure

the

maximum chain slack by pulling up and

pushing down the chain midway between the

engine sprocket and rear wheel sprocket.

Drive Chain Slack:

20 ∼ 30 mm (0.8 ∼ 1.2 in.)

.20∼ 30 mm (0.8 ∼ 1.2 in.)

•

If the drive chain is too tight or too loose, ad-

just it so that the chain slack will be within the

standard value.

WARNING

A chain that breaks or jumps off the

sprockets could snag on the engine

sprocket or lock the rear wheel, severely

damaging the motorcycle and causing

it to go out of control. Inspect the chain

for damage and proper adjustment.

16 PREPA

RATION

Drive Chain Slack Adjustment

•

Remove the cotter pin, and loosen the rear

axle nut.

•

Loosen the left and right chain adjuster lock-

nuts.

A. Rear Axle Nut

B. C

otter Pin

C. Chain Adjuster

D. Chain Adjuster Locknut

•

If the chain is too loose, turn in the left and

right chain adjusters evenly.

•

If the chain is too tight, turn out the left and

right chain adjusters evenly.

•

Turn both chain adjusters evenly until the

drive chain has the correct amount of slack.

To keep the chain and wheel properly aligned,

the notch on the l eft wheel alignment indi-

cator should align with the same swingarm

mark that the right indicator notch aligns with.

A. Marks

B. Notch

C. Indicator

D. Chain Adjuster

E. Chain Adjuster Locknut

NOTE

○Wheel alignment can also be checked using

the straightedge or string method.

•

Tighten both chain adjuster locknuts.

•

Tighten the rear axle nut to the specified

torque.

Torque: 98 N·m (10 kgf·m, 72 ft·lb)

•

Rotate the wheel, measure the chain slack

again at the tightest position, and readjust if

necessary.

•

Install a new cotter pin.

NOTE

○When inserting the cotter pin, if the slots in the

nut do not align with the cotter pin hole in the

axle, tighten the nut clockwise up to the next

alignment.

○It should be within 30 degrees.

○Loosen once and tighten again when the slot

goes past the nearest hole.

A. Cotter Pin

B. Turning Clockwise

•

Bend the cotter pin over the nut.

A. Cotter Pin

B. Nut

WARNING

A loose axle nut can lead to an acci-

dent resulting in serious injury or death.

Tighten the axle nut to the proper torque

and be sure the cotter pin is installed

correctly.

PREPARA

TION 17

•

Check the rear brake effectiveness.

Rear Shock Absorber

Spring Preload Inspection

•

Check the position of the spring preload ad-

juster on the rear shock absorber.

STD Spring Preload: No.2 position

A. Spring Preload Adjuster

B. No.2 Position

•

Turn the preload adjuster to the No.2 position.

Tire Air Pressures

•

To prevent flat-spotting during shipment, the

tires are over-inflated before crating. Adjust

the pressures to the specified values in the

front and rear, and make sure to tighten the

caps securely.

Tire Air Pressure [when cold]:

Front: 200 kPa (2.00 kgf/cm², 28 psi)

Rear: 225 kPa (2.25 kgf/cm², 32 psi)

A. Tire Air Pressure Gauge

Fuel

WARNING

Gasoline is extremely flammable and

can be explosive under certain condi-

tions, creating the potential for serious

burns. When filling the tank, turn the

ignition switch off. Do not smoke. Make

sure the area is well ventilated and free

from any source of flame or sparks; this

includes any appliance with a pilot light.

•

Open the fuel tank cap, and check for debris

in the fuel tank.

•

Fill

the fuel tank with one gallon or four liters

of unleaded gasoline. Use a gasoline with a

minimum octane rating shown below.

For US, Canadian and Brazil Specifica-

tions

Fuel Type Unleaded Gasoline

(RO

N+MON)

Minimum

Octane

Rating

Antiknock Index

For Other than US, Canadian and

Brazil Specifications

Use clean, fresh unleaded gasoline with an

octane rating equal to or higher than that shown

in the table.

Fuel Type Unleaded Gasoline

Minimum

Octane

Rating

Research Octane Number (RON)

•

Close the fuel tank cap. Check for any leaks.

Coolant

Coolant Level Inspection

•

Situate the motorcycle so that it is perpendic-

ular to the ground.

•

Check the coolant level through the coolant

level gauge on the reserve tank located to

the right of the front fork. The coolant level

should be between the F (Full) and L (Low)

level lines.

NOTE

○Check the level when the engine is cold (room

or atmospheric temperature).

18 PREPA

RATION

A. F (

Full) Level Line

B. L (Low) Level Line

C. Reserve Tank

•

If the amount of coolant is insufficient, add

coolant into the reserve tank.

Coolant Filling

•

Remove the cap from the reserve tank and

add coolant through the filler opening to the F

(Full) level line.

A. Reserve Tank Cap

B. Steering Stem Head Bolt

•

Install the reserve tank cap.

NOTE

○A permanent type of antifreeze is installed in

the cooling system when shipped. It is col-

ored green and contains ethylene glycol. It is

mixed at 50% and has the freezing point of

–35°C (–31°F).

Engine Oil (4-stroke)

Engine

Oil Level Inspection

NOTE

○This vehicle’s engine is filled with 10W-40 oil

from the factory. DO NOT DRAIN and refill

the crankcase before use. Check oil level and

drain plug tightness.

Engin

e Oil Drain Plug Torque:

19.6 N·m (2.00 kgf·m, 14.5 ft·lb)

A. Engine Oil Drain Plug

•

Park the vehicle on level ground.

•

Before starting the engine, check that the en-

gine has oil.

•

With the motorcycle held level, check that the

engine has oil through the oil level inspection

window in the lower right side of the engine.

NOTICE

If the engine is run without oil, it will be

severely damaged.

•

Start the engine and run it for several minutes

at idle speed. Stop the engine, then wait sev-

eral minutes until the oil settles.

•

With the motorcycle held level, check the en-

gine oil level through the oil level inspection

window. The oil level should come up be-

tween the upper and lower level lines next to

the oil level inspection window.

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Kawasaki Ninja 300 Assembly & Preparation Manual

Brand: Kawasaki

Model: Ninja 300

Category: Motorcycles

Type: Assembly & Preparation Manual

This manual is also suitable for

Ninja 300 ABS

Kawasaki Ninja 300 ABS is a motorcycle that has been partially disassembled for shipping purposes. Once assembled, it offers a range of capabilities:

Battery: The sealed battery never needs refilling and has been activated for optimal performance.
Brakes: The front and rear brake discs have been cleaned using oilless solvent to ensure effective braking.
Cables and Hoses: All cables, wiring leads and hoses have been correctly routed for smooth operation.
Clutch: The clutch cable has been greased and correctly fitted for efficient gear shifting.

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Kawasaki Ninja 300 Assembly & Preparation Manual

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Kawasaki Ninja 300 Assembly & Preparation Manual

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